Methods of producing light weight cement-like building products

Abstract

This invention is related to a procedure to produce paste for stone quarry, calcareous stones and other porous stony finishing, similar to cement or mortar, which comprises the combination of resin with calcium carbonate, silica grit or river sand aggregate, to give body to the resin. The aggregate can be mixed with cement and be pigmented in different colors and milled in diverse grain sizes for example, to obtain a perfect copy of stone quarry. It is possible also, to use additives like cobalt and catalysts to protect resin from ultraviolet rays or from flames, in case the binding paste comes in contact with fire. Additionally, the binding paste comprises quantities of water to produce cavities for porosity. It also contains a silica product named Aerosil, which allows the paste to become more dense to help its laying in the mold, without the necessity to pour as a liquid. If the paste is too dense it can be diluted with monomers. Detergent is used to ease the laying of the paste in the mold by hand. Fiberglass filament is used to improve the mechanical qualities.

What I claim is: 
     
       1. The method of producing cement like building products comprising the steps of: mixing calcium carbonate, silica grit, sand, and polyester resins, and   adding water to form a moldable paste comprising an exothermic self adhering uncured composition that can be molded by hand and which cures within two hours into a light weight product produced by exothermic reaction of the water to entrap air bubbles making the product porous.   
     
     
       2. The method of claim 1 further comprising the step of: manually kneading the uncured paste with soap foam on the hands.   
     
     
       3. The method of claim 1 further comprising the step of: applying the kneaded uncured paste to a cured product for obtaining a surface design.   
     
     
       4. The method of claim 1 further comprising the steps of: applying the kneaded uncured paste to a cured product to repair a crack, letting the uncured paste cure in-situ and grinding the surface after the paste is cured.   
     
     
       5. The method of claim 1 further comprising the step of: adding cobalt to the mixture for fireproofing.   
     
     
       6. The method of claim 1 further comprising the step of: adding fiberglass to the mixture for strength and rigidity of the cured product.   
     
     
       7. The method of claim 1 further comprising the step of: adding pigments to the mixture for simulating quarried products in the cured product.   
     
     
       8. The method of claim 1 further comprising the step of: treating the surface of the cured product by sandblasting to expose open cavities formed by the air bubbles.   
     
     
       9. The method of claim 1 further comprising the step of: treating the surface of the cured product with hydrochloric acid to expose open cavities formed by the air bubbles.   
     
     
       10. The method of claim 1 further comprising the step of: self-adhering the uncured paste to an arch to cure in place.   
     
     
       11. The method of claim 1 further comprising the steps of: securing the cured product to a concrete building structure by securing wire anchors between the concrete building and cured product by said uncured paste and letting the uncured paste cure in-situ.   
     
     
       12. The method of claim 1 further comprising the steps of: securing the cured product to a steel building structure by securing metallic members to the cured product by said uncured paste, and letting the uncured paste cure in-situ.   
     
     
       13. The method of claim 1 further comprising the step of: adding quarried stones to the mixture to simulate quarried products.   
     
     
       14. The method of claim 1 further comprising the step of: producing an artistic three dimensional design on the surface of the paste and curing the design in place.